Display Apparatus and Methods

ABSTRACT

A display includes a plurality of pixel chips, chixels, provided on a substrate. The chixels and the light emitters thereon may be shaped, sized and arranged to minimize chixel, pixel, and sub-pixel gaps and to provide a seamless look between adjacent display modules. The substrate may include light manipulators, such as filters, light converters and the like to manipulate the light emitted from light emitters of the chixels. The light manipulators may be arranged to minimize chixel gaps between adjacent chixels.

CROSS REFERENCE TO RELATED APPLICATIONS

This non-provisional utility application is a continuation of and claimspriority to application Ser. No. 15/806,988 filed Nov. 8, 2017.Application Ser. No. 15/806,988 is a continuation of non-provisionalutility application Ser. No. 15/497,330 filed Apr. 26, 2017, now patentU.S. Pat. No. 9,831,223. Application Ser. No. 15/497,330 is acontinuation of non-provisional utility application Ser. No. 14/878,041filed on Oct. 8, 2015. Application Ser. No. 14/878,041 is a continuationof non-provisional utility application Ser. No. 14/678,435 filed on Apr.3, 2015, now patent U.S. Pat. No. 9,159,707. Application Ser. No.14/678,435 is a continuation of non-provisional utility application Ser.No. 12/348,158 filed on Jan. 2, 2009, now U.S. Pat. No. 9,013,367.Application Ser. No. 12/348,158 is a non-provisional of U.S. provisionalApplication No. 61/019,144 filed Jan. 4, 2008. Application Ser. No.15/806,988, application Ser. No. 15/497,330, application Ser. No.14/878,041, application Ser. No. 14/678,435, application Ser. No.12/348,158 and Application No. 61/019,144 are incorporated herein byreference.

FIELD OF INVENTION

The present invention relates to display devices. More particularly, thepresent invention comprises a flexible display.

BACKGROUND

There has been increased interest in the development of flexibledisplays. It has proven difficult, however, to produce a large flexibledisplay, as manufacturing techniques used to produce small-scaledisplays have not proven readily scalable. Presently, large scaledisplays tend to be heavy, expensive, non-flexible, unreliable and powerhungry.

SUMMARY OF THE INVENTION

In one exemplary embodiment, a flexible display includes a plurality ofself-contained pixel-containing chips, called chixels, that are arrangedon a flexible substrate in a manner that provides sufficient bend radiusto the substrate to allow flexing of the display. The chixels mayinclude a sub-array of pixels provided on a rigid substrate that may bescaled to form a modular unit. A chixel can be combined with otherchixels on a flexible substrate so that multiple pixel sub-arrayscombine to form a large pixel array for a display. The chixels may berigid units of a predetermined size and shape and arranged on thedisplay substrate in a manner to provide a desired bend radius to thesubstrate and produce a display having a desired degree of flexibility.

The flexibility of the chixel display is a function of the bend gapsbetween the chixels. As used herein the term “bend gap” refers to thespace between adjacent chixels. Generally, the smaller the chixels, thegreater number of bend gaps and the more flexible the display. A chixelmay be formed in a particular shape and arranged on a flexible substratein such a way as to provide a chixel-based display of a desiredflexibility. For example, a chixel may be square-shaped and have an n×npixel arrangement, such as a 4×4 arrangement, to allow similarflexibility in both the horizontal and vertical planes. To increaseflexibility in one particular plane more than another, the size of thechixel in that particular plane may be decreased to provide more bendingpoints. For example, a pixel arrangement including elongatedrectangular-shaped chixels having a 4-row×8-column pixel arrangementthereon may provide twice as many vertical gaps as horizontal gaps andthereby provide greater lateral flexibility. Furthermore, chixels ofdifferent sizes or shapes may be incorporated into a display tocustomize the flexibility of different portions of the display.

In an exemplary embodiment of a chixel, a plurality of light emitters isprovided on a rigid substrate and serves as sub-pixels of a display. Thesub-pixels may be divided into groupings, such as groupings of threesub-pixels, to form pixels. For example, sub-pixels that emit red, greenand blue light may be grouped together to form an RGB pixel. Otherarrangements, such as by way of example and not limitation, include amono-color display in which all sub-pixels or pixels emit the same colorlight. Additionally, the light emitted by the pixels or sub-pixels maybe converted or filtered to provide the desired light output; forexample, the pixels could be formed of blue LEDs that are filtered orare color converted and filtered.

The sub-pixels may be of rectangular shape so that when combined withother sub-pixels they form a square pixel. For example, each sub-pixelmay be of a size ⅓x×x, so that three sub-pixels placed side-by-side forma square pixel of size x×x. The pixels may be arranged on the substratesuch that the space between adjacent pixels, referred to herein as a“pixel gap,” is of a desired distance d1. Because there are no pixels toproduce light at the pixel gap, the gap may appear as a darkened area ofa display, referred to as a “pixel gap line.” Similarly, the sub-pixelsmay be uniformly spaced so that space between sub-pixels, the “sub-pixelgap”, is of a desired size.

In one aspect of the invention, the pixels are of a size relative to thepixel gap to make the pixel gap line less noticeable to a viewer. Forexample, the pixels may be of a size relative to the size of the pixelgap so as to provide a display of a desired resolution in which thepixel gap is not as pronounced or distracting to the viewer. Thisrelationship and sizing may depend on a number of factors, including,but not limited to, viewing distance, contrast ratio, brightness, andviewing environment.

As mentioned above, the chixels are provided on the flexible displaysubstrate adjacent other chixels. The distance between the chixels isreferred to herein as a “chixel gap.” In an exemplary embodiment thechixels are arranged so that the chixel gap is minimized and the “pixelgap” between adjacent pixels is uniform throughout the display, evenacross adjacent chixels. In another exemplary embodiment the sub-pixelgaps are uniform within a chixel as well as between adjacent chixels.

The sub-pixels and pixels of the chixels may comprise various lightemitters. In one exemplary embodiment, a chixel comprises sub-pixels andpixels formed of light emitted diodes (LEDs). In an exemplary method ofmaking an LED-based chixel, a plurality of LEDs is prepared on a rigidsubstrate. For example, an n-doped layer and a p-doped layer areprovided on a rigid substrate, such as glass or sapphire wafer to formLED layers. Various layers may be used in the LED manufacturing processto produce LEDs which emit light with desired properties. For example,various phosphor layers may be used to produce light of desiredwavelengths and color. These layers may be provided to the bottom of thesubstrate. For example, a photo-conversion layer may be provided on thebottom of the rigid substrate to convert blue emitted light into whitelight which is more efficiently filtered to different colors. In oneexemplary embodiment of the invention, a light manipulator may be added.For example, filters made of co-extruded poly-carbonate plastics,surface coated plastics, or deep dyed polyesters may be provided toconvert the light emitted from the LEDs to a light with desiredcharacteristics. For example, most filters are subtractive, allowingonly a portion of the emitted light to pass through the filter. Forexample, filters and color conversion techniques may be used to providelight of desired properties. For example, filters may be used to producered and green light from emitted blue light. The dyes for the filtersmay be optimized to produce the desired wavelength of light output fromthe light emitted from the LED. A color conversion phosphor may bedeposited over the blue LEDs to produce a white light emission that maythen be filtered into desired colors, such as red, blue, and green. Thefilter film could be provided to the chixel or to the flexible substrateto which the chixels are attached.

Portions of the LED layers may then be removed by etching or other knowntechniques to form a plurality of spaced-apart LED stacks that share thesame substrate. For example, portions of the LED layers could be removeddown to the rigid substrate so as to provide LED stacks that share thesame substrate. The particular size of the LED stacks can vary accordingto the use of the display. For example, for displays meant for closeviewing the LEDs can be etched into smaller stacks than displays meantfor viewing at greater distances.

Contacts may then be provided to the LED stacks to form a plurality ofspaced apart LEDs on a rigid substrate that together form an LED wafer.The LEDs may be provided with rear contacts so that rear display driversmay be used to drive the display in which the chixels are incorporated.For example, a portion of the p-doped layer of the LED stack may beremoved ex pose the n-doped layer in order to provide an n-contact areaat the top end of the LED stack. This allows for conductor wires to thecontact to extend upwardly from the display and diminishes the need forspace between LEDs for the contact. A p-contact may also be provided atthe top of the stack to form a rear-drivable LED.

The LED wafer may then be subdivided into smaller portions that definechixels, each chixel having a plurality of LEDs that will serve assub-pixels. The chixels can then be placed on a flexible substrate in anarrangement that allows bending between the chixels and provided withdrive means to form a flexible display. This manufacturing processallows for accurate spacing between the LEDs by using masking, etchingor other known techniques that produce uniformly spaced sub-pixels.Furthermore, the process allows for the accurate arrangement ofsub-pixels between chixels and, therefore, uniform sub-pixel placementthroughout a display as well as minimal sub-pixel, pixel, and chixelgaps.

Traditionally an LED wafer is diced into individual LEDs that are thenhoused in separated LED assemblies. These separate LED assemblies arethen incorporated into a display as individual sub-pixels. Due to theindividual housings of the LEDs, however, that method results indisplays with non-uniform sub-pixel or pixel spacing and large sub-pixelgaps and pixel gaps. Furthermore, each individual LED must be providedseparately into the display, resulting in a large number ofmanufacturing operations.

Chixels may be formed by halting an LED wafer production process beforethe substrate is diced to form discrete LEDs. In a typical process forproducing blue emitting LEDs, a layer of p-doped gallium nitride isdeposited on a 2″ sapphire wafer. Then, a layer of n-doped galliumnitride is deposited. A photo-mask is deposited and the gallium nitridelayers are selectively photo-etched to create individual LED units andtheir respective electrodes. In the manufacture of discrete LEDs, thewafer would then be diced, and the LEDs would be packaged. In the chixelproduction process, the wafer is diced, but instead of discrete LEDs,the dicing is performed so that the resulting diced pieces hold x×xarrays of LEDs.

Under an exemplary method of the present invention, multiple LEDs sharea single LED substrate by cutting the LED wafer into larger units,chixels, that comprise a plurality of LEDs that define sub-pixels andtogether form pixels of a display. This allows for uniform spacingbetween the LEDs, and therefore uniform spacing between sub-pixels andpixels and results in smaller sub-pixel and pixel gaps. By manufacturingthe LEDs on the same rigid wafer substrate, the pitch of the LEDs can betightly controlled during the LED wafer manufacturing process usingmasking, etching and other techniques thereby providing a uniformsub-pixel and pixel pitch. The LEDs may be provided with contacts and adrive means to form workable sub-pixels of a display.

Furthermore, the exemplary method allows for different chixel sizes andshapes to be selected during the dicing process and is easily adjustableto different sub-pixel sizes by changing the etching process. Forexample, an LED wafer may be grown having LEDs of a size 320 micronssquare and separated by 320 microns on each side and then separated intosub-units of 96 LEDs, each LED corresponding to a sub-pixel of adisplay. For example, the 96 LEDs may correspond to 8 rows of 12sub-pixels. The sub-pixels may be grouped into three to define pixels toform a 4×8 pixel arrangement. Or the LED wafer may be divided intochixels having 48 LED sub-pixels to form a 4×4 pixel arrangement. Thesub-pixel size can be changed by simply using a different etching maskand the chixel size by changing the dicing cut lines.

A plurality of chixels, having a plurality of light emitters, which willserve as sub-pixels of a display, may be arranged on a flexiblesubstrate to produce a flexible display. In one exemplary method thechixels are placed light-emitting end down onto a flexible substrate soas to transmit light through the flexible substrate. The chixels may bearranged at a predetermined spacing to produce a desired chixel gap toprovide a desired bend radius to the flexible substrate. Drive means maybe provided to the chixels to power the light emitters for emittinglight. The drive means may include a controller to control the lightemitted from each light emitter (sub-pixel) to produce a desired imageon the display. In one exemplary embodiment a controller is provided foreach chixel to produce a chixel-partitioned display. This has theadvantage of decreasing the number and length of wires and distributesthe size of the controller unit out among the chixels, possibly reducingthe bulk of the display electronics by subdividing them into smaller,though more numerous, units.

In one exemplary embodiment a flexible substrate that may be used inconjunction with the chixels includes a diffusion layer, a contrastenhancement layer, and a hardened outer layer. The chixels may beattached to the flexible substrate by an adhesive or other means so thatlight emitted from the chixel is transmitted through the flexiblesubstrate. The flexible substrate may also include one or more filtersto manipulate the light emitted from the LEDs. For example, thesubstrate may include an arrangement of red, green and blue filters thatcorrespond to the location of light emitters of the chixels to providered, green and blue sub-pixels of the display.

It is possible to produce an RGB display using monocolor LEDs and eitherfilters or color conversion and filters. Both techniques use blue(gallium nitride, GaN) LEDs. In the first embodiment, blue LEDs may befiltered to allow only red or green wavelengths of light to be emitted.In this case, the blue would not be further filtered for blue lightemission unless it was desirable to emit a different color point. In thesecond embodiment, a white color conversion phosphor is deposited overthe blue LEDs. This results in white light emission that can then befiltered into red, green and blue. The filtering of white to RGB is moreefficient than the filtering of blue to red or green. The filters usedin these embodiments could be provided in the form of a flexible filmonto which the appropriate dyes and/or filter materials have beenprinted in the desired pattern. An example of this type of film is thatused 011 backlit LCD laptop monitors. In an effort to make the chixelgap less noticeable to the viewer, the filter film area corresponding tothe edge of a chixel may be printed with the pixel shape rotated 900,and LEDs from both adjacent chixels will light the rotated pixel.

In one exemplary embodiment, in which blue LEDs are used, red and greenfilters may be provided 10 make RGB pixels. As discussed above, the LEDsof the chixel may include a photo-conversion layer so that the LEDs emitwhite light, in which case red, green, and blue filters may be used.Arrangements other than standard RGB pattern may be used. For example,in one exemplary embodiment, filters are arranged to minimize thesub-pixel, pixel, and chixel gap by providing filters that bridge twoadjacent chixels. For example, a red filter may be placed so as to coversub-pixels from two different chixels. Furthermore, although discussedas one light emitter to one sub-pixel, multiple light emitters may beused for one sub-pixel. For example, each colored filter may includethree LEDs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a flexible display in accordance with an exemplaryembodiment of the invention.

FIG. 2 shows an enlarged view of a portion of the display of FIG. 1along cut line 2-2.

FIGS. 3A-3B show a side view of a flexible chixel display in accordancewith an exemplary embodiment of the invention.

FIG. 4 shows a chixel in accordance with an exemplary embodiment of theinvention.

FIG. 5 shows a flexible display which incorporates square-shaped chixelsin accordance with an exemplary embodiment of the invention.

FIG. 6 shows a flexible display which incorporates square-shaped chixelsof FIG. 5.

FIG. 7 shows an elongated chixel in accordance with an exemplaryembodiment of the invention.

FIG. 8 shows a flexible display incorporating the elongated chixels ofFIG. 7.

FIG. 9 shows a chixel-based display in accordance with an exemplaryembodiment of the invention.

FIG. 10 shows an enlarged portion of the chixel-based arrangement ofFIG. 9.

FIG. 11 shows an LED wafer in accordance with an exemplary embodiment ofthe invention.

FIG. 12 shows a side view of the wafer of FIG. 11.

FIG. 13 shows an LED stack of the wafer of FIG. 11.

FIG. 14 shows a side view of an LED of a chixel in accordance with anexemplary embodiment of the invention.

FIG. 15 shows a top view of the LED of FIG. 14.

FIG. 16 shows a white light emitting LED of a chixel in accordance withan exemplary embodiment of the invention.

FIG. 17 shows an alternative embodiment of a chixel LED.

FIG. 18A shows a top view of an LED wafer in accordance with anexemplary embodiment of the invention.

FIG. 18B shows an enlarged portion of the LED wafer of FIG. 18A.

FIG. 19 shows a chixel separated from the LED wafer of FIG. 18A inaccordance with an exemplary embodiment of the invention.

FIG. 20 shows the chixel of FIG. 19 incorporated into a display.

FIG. 21 sows an enlarged portion of the display of FIG. 20.

FIG. 22 shows a display substrate in accordance with an exemplaryembodiment of the invention.

FIG. 23 shows a side view of a chixel-based display.

FIG. 24 shows a flexible chixel-based display in accordance with anexemplary embodiment of the invention.

FIG. 25 shows a flexible chixel-based display having dedicatedcontrollers for each chixel.

FIG. 26 shows a chixel and filter arrangement for a chixel-based displayin accordance with an exemplary embodiment of the invention.

FIG. 27 a chixel-based display incorporating the chixel and filter ofFIG. 26.

FIG. 28 shows an exemplary embodiment of a chixel having additional edgelight emitters.

FIG. 29 shows a color flexible chixel-based display incorporating thechixel of FIG. 28.

FIG. 30 shows an enlarged portion of the display of FIG. 29.

FIG. 31 shows an exemplary embodiment of filter pattern.

FIG. 32 shows an exemplary chixel and filter arrangement.

DETAILED DESCRIPTION

As required, exemplary embodiments of the present invention aredisclosed herein. These embodiments are meant to be examples of variousways of implementing the invention and it will be understood that theinvention may be embodied in alternative forms. The figures are not toscale and some features may be exaggerated or minimized to show detailsof particular elements, while related elements may have been eliminatedto prevent obscuring novel aspects. Therefore, specific structural andfunctional details disclosed herein are not to be interpreted aslimiting, but merely as a basis for the claims and as a representativebasis for teaching one skilled in the art to variously employ thepresent invention.

For purposes of teaching and not limitation, the exemplary embodimentsdisclosed here in are discussed mainly in the context of LED lightemitter technologies. However, the present invention is applicable toother light emitting technologies as well, such as, by way of exampleand not limitation, backlit LEDs, electro-luminescence, or plasma tubesor cells.

Turning to the figures where like elements have like reference numbersthroughout the several views, FIG. 1 shows an exemplary embodiment of aflexible display 100. As shown in FIG. 2, the flexible display 100 iscomprised of a plurality of pixel chips 202, referred to herein aschixels 202, that are arranged in a chixel arrangement 200. The chixels202 may be rigid self-contained components that include a plurality ofpixels 204, formed of sub-pixels 206. The chixels 202 are of asufficiently small size and attached to a flexible display substrate 208in such a manner that the space between the chixels, referred to hereinas a chixel gap 304, allows the flexible display substrate 208 to have abending radius to provide a desired flexibility to the display 100.

For example, as shown in FIG. 3A, chixels 202 are provided on a flexibledisplay substrate 208 with a chixel gap 304 of a size so that the sideedges of the chixels are parallel when the substrate 208 is flat. Asshown in FIG. 3B, as the substrate 208 flexes, the chixels 202 move atangles with respect to one another due to the bending of the substrate208 at the chixel gaps 304. Although shown as square chixels 202 withsharp upper corners, the chixels 202 could have rounded corners or othershapes to prevent contact between adjacent chixels 202 during bending ofthe substrate 208. Furthermore, the chixels 202 could be shaped so as tolimit or prevent flexing of the substrate in a particular direction. Forexample, the chixels could have extensions (not shown) that contact eachother to limit movement when the display is flexed in a particulardirection. The size of the chixels and spacing between the chixels couldalso be varied to provide desired flexibility. For example, smallerchixels could be used on portions of the display which require moreflexibility and larger chixels used on portions with lower flexibilityrequirements.

The chixels 202 are of a predetermined shape and arranged in a desiredpattern on a flexible substrate 208 to form a flexible display 100. Thesize, shape, and arrangement of the chixels 202 may be selected toprovide a desired bend radius to the flexible substrate 208 to which thechixels 202 are incorporated.

As shown in an exemplary embodiment in FIG. 4, a chixel 202 may begenerally square in shape. For example, the chixel may comprise a 4×4array of 16 pixels 204, each pixel having three sub-pixels 206. As shownin FIG. 5, this square shape allows a chixel-based display 500 in whichthe chixels 206 are incorporated to flex easily both horizontally andvertically between the chixels 202 as the ratio of vertical andhorizontal chixels gaps 304 is the same. FIG. 6 shows a chixel displayhaving chixels 202 on a flexible substrate with sufficient bend radiusto be rolled up into a tube having a radius of approximated by:

$r = {{\frac{n - \pi}{2\pi}x} + {\frac{ns}{8\pi \; x}\sqrt{{4x^{2}} - s^{2}}}}$

Where:

x=width of a chixel;

s=width of space between chixels; and

n=number of chixels in the tube; and provided that n≥4; x≥0.5 s, andassuming the tube cross-section is circular.

Chixels 202 may be provided in other shapes and arranged to provide achixel gap 304 of an appropriate size to provide the display 100 with adesired amount of flexibility. Generally, the smaller the chixel 202,the greater the number of chixel gaps 304 in the display in which thechixels are incorporated and the greater the number of bending pointsthat can be provided and, therefore, the greater the flexibility of thedisplay. For example, if it is desirable to provide a greater amount offlexibility in one direction of the substrate than another then thechixels can be shaped to provide such flexibility by arranging a largernumber of flexible gaps in the one direction than the other.

The chixel 702 shown in FIG. 7 includes a 4×8 pixel arrangement. Asshown in FIG. 8, this allows for greater lateral bending because thereare approximately twice as many vertical bending points 804 in thedisplay than horizontal bending 806 points. Although the smaller thechixel, the greater the number of chixel gaps and the greater theflexibility of the display, the fewer the number of pixels that can beprovided on the chixel and/or the smaller the pixels. Thus, while havingsmaller chixels increases flexibility, having larger chixels increasesthe size and/or number of pixels that can be provided on each chixel anddecreases the number of chixels that must be attached to the flexiblesubstrate. Thus, smaller chixels could be used in areas of the displaywith higher flexibility requirements.

As shown in FIG. 4, a chixel 202 may include pixels 204 that arecomprised of sub-pixels 206. The sub-pixels 206 may have differentproperties in order to provide desired properties for the pixel 204 ofwhich they form a part. For example, the pixels 204 may comprise red206A, green 206B, and blue 206C sub-pixels that together form an RGBpixel. The intensity of the individual sub-pixels 206A, 206B, 206B canbe manipulated to provide light having desired characteristics, such asa desired light color or brightness. The sub-pixels 206 may have arectangular shape so that together they form a square-shaped pixel 204.For example, each sub-pixel may have dimensions of ⅓ mm×1 mm to form apixel of 1 mm̂2. The pixels 204 may be provided in a 4×4 array on a rigidsubstrate 220 to form a chixel of about 4 mm̂2. The substrate 220 may betransparent to allow light emission through the substrate. For example,the substrate may be rigid glass or sapphire as discussed in more detailbelow.

The pixels 204 may be provided at a distance apart from one another, thedistance referred to as a “pixel gap” 304. The size of the pixel gap 304may vary depending upon the particular light emitting technology usedfor the sub-pixel 206. For example, some light emitters may requireconductors that extend around the edge of the emitter, which preventsthe light emitters from directly abutting each other, thereby resultingin large sub-pixel and pixel gaps. For example, Organic Light EmittingDiodes (OLEDS) generally require that current be provided through thefront of the display and a contact is commonly arranged to extend aroundthe edge of the OLED, thereby preventing OLEDs from being tightly packedin a display.

One problem with prior art displays is that the pixel gap 304 is of suchsize that gap lines are visible in the resulting display which isdistracting to a viewer and renders an image of poorer quality. This ledto prior art attempts to provide front conductors for the pixels. Thisfront conductor approach raises additional problems in producingflexible displays, however, due to the limited flexibility and highresistance values of known transparent front electrodes.

In one aspect of the present invention, the pixels 204 are sizedrelative to the pixel gap 306 between the pixels 204 such that the pixelgap 306 is less noticeable to an observer. For example, in a prior artOLED device the gaps between pixels that are required for thewrap-around electrodes can result in a pixel gap to pixel area ratiothat is readily noticeable to a viewer of the display.

In the present invention, pixels 204 are sized relative to the pixel gap306 so that the gap line is less noticeable while still providing adesired resolution. For example, in the exemplary embodiment shown inFIG. 4, the pixel gap d2 may be 0.25 mm and the pixel size (width orheight) 1 mm to produce a pixel gap to pixel size ratio of 0.25 mm/1mm=0.25. Applicant has found that for a 120″ display at 1080p a pixelsize of 1 mm̂2 is desirable.

One advantage of the present invention is that if a 4 mm chixel 202which includes 16 pixels in a 4×4 array is used to provide the pixelsfor the display, the number of operations to provide the pixels 204 tothe display is 1/16 of that of a technique that attempts to attachindividual pixels to a display because multiple pixels are added with asingle chixel. As discussed in more detail below, minimizing the effectof the gap line allows for the use of manufacturing techniques andresulting structures that were previously avoided due to concerns overgap lines. For example, by adjusting the pixel size to the pixel gap tominimize the effect of a gap line allows for electrodes to extend aroundthe side of a pixel and allow a display to be driven at the rear,thereby eliminating some of the problems with prior art devices that arefront driven.

As shown in FIG. 9, chixels 202 may be coupled to a flexible displaysubstrate 208 by an adhesive or other coupling means. The pixels 204 canbe arranged on the chixel 202 with uniform pixel spacing of a pitch orpixel gap d2. The chixels 202 can be arranged on the flexible displaysubstrate 208, to maintain the uniform pixel gap 304 d2 between adjacentchixels 202A, 202B. For example, the pixels 202 may be located near theedges 910A-B of the chixels 202 and adjacent chixels 202A-B arranged sothat the pixel gap 306 is uniform between pixels 204 even acrossadjacent chixels 202A, 202B. As discussed above, the chixel gap 304between the chixels 202 provides a desired bend radius to the flexiblesubstrate 208 that allows the display 100 to flex. Thus, a uniform pixelgap and a desired flexibility can be obtained; in other words the pixelpitch is consistent in both the rows and columns, even between pixels onthe edges of two adjacent chixels. In one exemplary embodiment the pixelgap may be 320 micron, the chixel gap 320 micron and the pixel size 1600micron.

As discussed in more detail below, the flexible substrate 208 maycomprise a variety of layers, such as by way of example and notlimitation, a contrast layer, a diffusion layer, a filter layer, and ananti-reflection layer. Each of these layers may be of a flexible plastictype. Thus, even though the chixels 202 themselves may be rigid, asufficient number of chixel gaps 304 are provided in an appropriatearrangement that a desired bend radius of the flexible substrate 208 isobtained.

Chixels 202 may employ different light emitting technologies, such asLED, electro-luminescence, plasma tubes or cells, and backlit LCD. FIGS.11 and 12 show an exemplary method of manufacturing an LED-based chixel.An LED is formed by depositing an n-doped semiconductor and a p-dopedsemiconductor layer on a substrate. Light is formed at the p-n junctionwhen it is excited by electrical current. As shown in FIG. 11 an LEDwafer 1100 may be produced that includes a plurality of spaced apart LEDstacks 1104 that, as discussed in more detail below, may serve as lightemitters for a flexible display. As shown in FIG. 12 the LED wafer 1100may comprise a rigid substrate 1102 having a plurality of LED stacks1104 thereon. For example, as shown in FIG. 13 an LED stack 1104 mayinclude a p-doped layer 1106 and an n-doped layer 1108 that are providedatop a sapphire substrate 1102 and have the appropriate properties toemit light when supplied with an appropriate charge (current).

Various techniques can be used to create the LED stacks with greataccuracy. Portions of the layers 1106, 1108 may be removed to createseparate LED stacks on the rigid substrate separated from one another bya gap 1110 that generally corresponds to a sub-pixel or pixel gap of acompleted display. For example, a mask may be applied and etchingtechniques used to etch channels through the upper layers 1106, 1108down to the substrate to produce stacks that share a common substrate1102. In an exemplary embodiment LED stacks may be generally squarehaving a length of about 320 um and a width of about 320 um and a gapbetween the LED stacks 1104 of about 50 um. Applicant has found that alayer of n-GaN of about 0.2 um thickness and a p-GaN layer of about a0.2 um thickness on a sapphire substrate of a thickness of about 350 umcan be used to produce LEDs that emit blue light having a wavelength ofabout 450 nm. Different layers may be used or additional layers added tothe LED stacks to obtain LEDs that emit light with desiredcharacteristics. Furthermore, as discussed in more detail below,filters, photoconverters, and other apparatus may be used to manipulatethe light emitted from the LEDs.

In order to make the LED stacks 1104 into workable LEDs, a p-contact1120 and an n-contact 1122 may be provided to the stacks 1104 as shownin FIG. 14 to form an LED 1400. The p-contact 1120 may be provided in acutout area 1130 of the p-doped layer 1108. For example, an etchingprocess may be used to remove a portion of the p-doped layer to allowthe n-contact 1122 to be placed directly on top of the n-doped layer1106. This allows the p-contact to be placed directly atop of then-doped layer 1106 and conductors 1140 to extend upward from the LED toa rear mounted display driver when the LEDs are incorporated into adisplay. This obviates the need of providing a large space between thelight emitters for providing a pathway for conductors running along theedge and side of the light emitter and thereby allows the LEDs to betightly packed. The wafer may be processed by etching, ablation, orother known techniques to form LEDs of various shapes, such as the LED1700 shown in FIG. 17 and arranged in a desired arrangement.

Additional layers can also be added to the LEDs 1400. For example, asshown in an exemplary LED 1600 in FIG. 16 a luminescent phosphor layer1610, typically a powder phosphor formulated based on the light outputof the LED to provide the best conversion, may be provided for colorconversion, to convert the emitted blue light to white. The colorconversion layer 1610 may be added by known techniques. As shown inFIGS. 14 and 16 when all appropriate current is applied, light istransmitted downwardly from the LED 1400, 1600. Thus, in theseembodiments the substrate 1102 is transmissive.

The wafer 1100 may include different layers on different LED stacks toprovide different light characteristics. For example, different layerscould be used to produce red, blue, and green light from different LEDstacks 1104. The wafer 1100 could also be made of uniform LED stacks1104 having the same or similar properties. For example, the LED stacks1104 could be constructed to emit white light or blue light which couldthen be filtered to produce light with desired characteristics. In theexemplary embodiment shown in FIG. 14 in which GaN layers are used, bluelight is emitted. Filters may also be used to provide red, green andblue LEDs which could define red, green and blue sub-pixels of an RGBpixel display. As seen in FIG. 16 a white phosphor photo-conversionlayer 1610 can be applied so that the light emitted from the LED 1600 iswhite which is more efficiently filtered than blue light.

As shown in FIGS. 18A-B an LED wafer 1800 may include an array ofuniformly spaced rectangular-shaped LEDs 1802. The LEDs 1802 definesub-pixels 1803 that may be incorporated into a flexible display. Thesub-pixels 1803 are spaced apart a horizontal distance h1 that forms asub-pixel gap 1808. A group of LEDs, such as three LEDs, may be used todefine an addressable pixel 1804 for a display. A larger array of LEDsmay define a chixel 1806 which may include multiple sub-pixels andpixels. In the exemplary embodiment shown in FIG. 19 the chixel 1806includes 8 rows of 12 LEDs which define 96 sub-pixels and 32 three-LEDpixels 1804 of the chixel 1806 to provide a 4×8 pixel arrangement.Commands/instruct ions from a driver may be directed to the LEDs of thepixel grouping to manipulate the individual LEDs 1802 as sub-pixels sothat the overall light produced by the pixel 1804 is of desiredcharacteristics, such as a desired color and brightness.

Multiple chixels 1806 may be coupled to a flexible substrate 208 to forma flexible display 2000. For example, as shown in FIG. 20 chixels 1806may be coupled to a flexible substrate 208 in an arrangement 2202. Thearrangement of the sub-pixels 1803 on the individual chixel 1806 inconjunction with the arrangement of the chixels 1806 on the substrate208 may be such as to provide uniform LED spacing and hence uniformsub-pixel and pixel spacing across the display 100. In addition, thepixel gap 306 may be uniform across the display and may be set equal tothe pixel gap 308. By providing the sub-pixels 1802 about the edge ofthe chixel 1806, and removing a predetermined amount of the substrate208 in the dicing process, the chixel gap 304 may be such that the pixelgap 306 between pixels on adjacent chixels 202 is the same as the pixelgap between pixels on the same chixel and the pixel gap is equal to thesubpixel gap. This provides for a uniform display with minimal gaplines. While discussed primarily in terms of the lateral spacing of thesub-pixels, pixels, and chixels, the same principles apply to thespacing of the sub-pixels, pixels, and chixels in other directions, suchas the vertical gaps.

The size of the pixels 1804 can be varied depending upon the desiredresolution and use of the display. For example, the size of thesub-pixels and pixels 1804 within a chixel 1806 incorporated into adisplay intended for use at a viewing distance of 10 feet may be smallerthan a display meant to be used at a viewing distance of 100 feet, eventhough the displays have the same resolution.

As discussed above, the chixels 202 may be coupled to a flexiblesubstrate 208 to form a flexible display 100. In addition to providingsupport to the chixels 202 the substrate 208 may also provide additionalfunctions, such as filtering, light diffusion, contrast enhancement,etc., and may be comprised of multiple layers. An exemplary flexiblesubstrate 2200 shown in FIG. 22 comprises a diffusion layer 2202, acontrast enhancement layer 2204, and an outer protective layer 2206. Theflexible substrate 2200 may also include an adhesive layer 2208 forcoupling chixels 202 to the flexible substrate 2200 and one or morefilters 22 1 0, as well as an anti-reflective layer 2212 (not shown).

The chixels 1600 may be placed light-emitting end down on the substrate208 as shown in FIG. 23 so as to emit light through the flexiblesubstrate 2200. The exposed p 1120 and n 1122 contacts allow the displayto be driven from the rear by a drive system 2402 as shown in FIG. 23,thereby avoiding the complications of providing transparent frontelectrodes to the LED sub-pixels. As discussed above with reference toFIGS. 3A-3B the chixels 1600 are arranged on the substrate 2200 so thatthe resulting chixel gaps 304 provide sufficient bending areas to givethe substrate 2200 a desired amount of flexibility. The drive means mayaddress the sub-pixels in predetermined pixel groupings.

As shown in FIG. 22 the substrate may be provided with one or morefilters 2210 to manipulate the light emitted from the LED lightemitters. For example, an array of color filters can be printed, sprayedor otherwise provided to the substrate 2200. As seen in FIG. 26 ared-green-blue filter arrangement 2602 having filter portions 2604A,2604B, 2604C of red R, green G and blue B may be added to the substrateassembly 2200 to form a filtered substrate 2702 with filter portions2604 that correspond with the different LED light emitters 1600A, 1600B,1600C of a chixel 1600. The chixel 1600 is coupled to the filteredsubstrate to form a color display 2700 so that the light emitters 1600align with the filtered portions 2604 to form RGB pixels 2702A, 2702B,2702C as shown in FIG. 27.

As shown in FIG. 24 drive means 2402 may be provided to the chixels toprovide the necessary power and commands to make the light emitters ofthe chixels emit light in a desired manner. The drive means 2402 mayinclude drive electronics as known in the art. In the exemplaryembodiment shown in FIG. 25, a controller 2502 is provided for eachchixel. The controller 2502 may comprise a data line and a power linethat controls the emission of light from each of the light emitters on aparticular chixel 1600. By providing individual chixels with acontroller 2502, chixel units can be provided which can be pre-made andready to install in a display.

Other filter arrangements may be provided in lieu of the standard RGBfilter arrangement discussed above, in which each filter covers a singlelight emitter. For example, in the exemplary embodiment shown in FIGS.28-30 edge filters 2804 are arranged horizontally to cover portions ofmore than one light emitter. These edge filters further minimize theeffect of the chixel gaps 304. In addition, the chixels may be sized toinclude edge light emitters in addition to standard three sub-pixelmultiples.

Chixel gaps may to be more noticeable when the display 100 is flexedinto a non-flat condition. As shown in FIG. 28 in addition to thestandard lateral RGB filter arrangement of the filter arrangement 2602in FIG. 26, the filters that correspond to light emitters 1600 at theouter edge of a chixel 2802 referred to as edge emitters 2810 may besized and shaped to cover edge emitters of two adjacent chixels 2802.For example, edge filters 2804 may be provided to bridge the chixel gap304 between adjacent chixels 2802 and cover edge light emitters 2810 oneach chixel 2802. These edge filters 2804 may be oriented horizontallyand may be of a size as to together cover an edge light emitter 2810 onadjacent chixels 2802 in a vertical RGB arrangement. For example, asshown in FIG. 28 a row of 14 light emitters 1600 on a chixel 2802include 12 center light emitters and two edge emitters 28 10. The chixel2802 may be arranged on a filtered substrate 2906 having vertical filterportions 2604 and edge filters 2804 so that the center 12 light emitters1600 correspond with a row of 12 vertically oriented red 2604A, green2604B or blue 2604C filters and the two edge light emitters 2810correspond with colored edge filters 2804A-C.

Instead of covering a single light emitter on one chixel, the edgefilter are sized and oriented to cover all edge light emitter 2810 oneach chixel thereby bridging the chixel gap. In addition, the edgefilters may be of a size such that multiple edge filters cover theadjacent light emitters. For example, red, green and blue edge filtersmay be arranged to cover adjacent edge light emitters in a vertical RGBpattern. The same may be done along the upper and lower edges ofadjacent chixels. In addition to having the 12 RGB filters whichcorrespond to 4 RGB pixels, an extra light emitter may be provided ateach edge of the chixel to form a row of 14 light emitters. Thus, whentwo chixels are placed next to one another two edge pixels/lightemitters are adjacent one another. It should be noted that while thesub-pixels and filters are generally discussed as corresponding with asingle light emitter, filters may cover multiple light emitters. Forexample, a sub-pixel of a chixel could include three vertically alignedlight emitters which could be cover by a red filter to define a redsub-pixel.

FIG. 31 shows another exemplary filter pattern 3102 that may be used inconjunction with a chixel 2802 in which upper and lower end filters 3104are elongated to filter adjacent upper and lower light emitters 2820across the chixel gap 304 in FIG. 32. Although each upper edge filter3104 is shown as a single color filter that covers two adjacent lightemitters from adjacent chixels 2802A-B, the filters could be sized sothat each light emitter is covered by a red, green, and blue filter.

What is claimed is:
 1. A display comprising: (a) a plurality of lightemitting rigid chixels affixed to a substrate, said plurality of lightemitting rigid chixels collectively providing a visible display, saiddisplay having both vertical and horizontal directions defined in theplane of said visible display; (b) each of said plurality of lightemitting rigid chixels comprising: i. one or more light emitting pixelscoupled to a rigid substrate, said rigid substrate having anon-functional edge and an adjacent region devoid of any conductor; ii.each of said one or more light emitting pixels comprising a plurality oflight emitting sub-pixels coupled to said rigid substrate to provide aspaced array of sub-pixels providing a plurality of sub-pixel gapsbetween adjacent light emitting sub-pixels in a vertical direction; iii.said plurality of light emitting sub-pixels comprising each of saidlight emitting pixel further characterized in that more than one colorof light may be produced by said light emitting pixel; iv. saidplurality of light emitting sub-pixels disposed in a linear arrangementwith respect to each other when viewed on said visible display, thedirection of said linear arrangement being parallel to said verticaldirection; v. wherein one of said plurality of light emitting sub-pixelsis a top sub-pixel disposed at a terminus of said linear arrangement,and wherein one of said plurality of light emitting sub-pixels is abottom sub-pixel disposed at another terminus of said lineararrangement; (c) said plurality of light emitting rigid chixels arrangedupon said substrate to provide a spaced array of chixels, said spacedarray of chixels providing a plurality of substantially equal pixel gapsdisposed across said non-functional edges between the top sub-pixel ofeach adjacent light emitting chixel in both said horizontal and saidvertical directions; (d) said spaced array of chixels further providinga plurality of substantially equal second pixel gaps disposed acrosssaid non-functional edges between the bottom sub-pixel of each adjacentlight emitting pixel in both said horizontal and said verticaldirections; (e) further characterized in that each of said plurality offirst pixel gaps is substantially equal to each of said plurality ofsaid second pixel gaps across said display.
 2. The display of claim 1,further characterized in that each of said plurality of light emittingrigid chixels is disposed upon said substrate such that thenon-functional edge of any light emitting rigid chixel does not overlapthe non-functional edge of any adjacent light emitting rigid chixel. 3.The display of claim 1, further characterized in that the rigidsubstrate of each of said plurality of light emitting rigid chixels issubstantially transparent and at least a portion of the light emitted bysaid light emitting rigid chixel is transmitted through said rigidsubstrate.
 4. The display of claim 1, further characterized in that aportion of said plurality of light emitting rigid chixels is disposedupon said substrate such that the non-functional edge of at least onelight emitting rigid chixel abuts the non-functional edge of an adjacentlight emitting rigid chixel.
 5. The display of claim 1, furthercharacterized in that said one or more light emitting pixels is aplurality of light emitting pixels coupled to said rigid substrate, afirst portion of said plurality of light emitting pixels effective toproduce a substantially red light emission, a second portion of saidplurality of light emitting pixels effective to produce a substantiallygreen light emission, and a third portion of said plurality of lightemitting pixels effective to produce a substantially blue lightemission.
 6. The display of claim 5 further characterized in that afourth portion of said plurality of light emitting pixels is effectiveto produce a substantially white light emission.
 7. The display of claim1, further characterized in that a first portion of said plurality ofsub-pixels is effective to produce a substantially red light emission, asecond portion of sub-pixels is effective to produce a substantiallygreen light emission, and a third portion of sub-pixels is effective toproduce a substantially blue light emission.
 8. The display of claim 7further characterized in that a fourth portion of sub-pixels iseffective to produce a substantially white light emission.
 9. Thedisplay of claim 1, further characterized in that each of said pluralityof light emitting rigid chixels consists of one pixel.
 10. The displayof claim 1, further characterized in that each of said plurality oflight emitting rigid chixels consists of one pixel, and, each pixelconsists of: a red sub-pixel, a green sub-pixel, and a blue sub pixel.11. A method of constructing a display module, the method comprising thesteps of: (a) providing a plurality of light emitting rigid chixels,each chixel comprising: i. one or more light emitting pixels coupled toa rigid substrate, each of the plurality having a non-functional edgeand an adjacent region devoid of any conductor; ii. each of said one ormore light emitting pixels comprising a plurality of light emittingsub-pixels coupled to said rigid substrate to provide a spaced array ofsub-pixels providing a plurality of sub-pixel gaps between adjacentlight emitting sub-pixels in a vertical direction; iii. said pluralityof light emitting sub-pixels comprising each of said light emittingpixel further characterized in that more than one color of light may beproduced by said light emitting pixel; iv. said plurality of lightemitting sub-pixels disposed in a linear arrangement with respect toeach other when viewed on said visible display, the direction of saidlinear arrangement being parallel to said vertical direction; v. whereinone of said plurality of light emitting sub-pixels is a top sub-pixeldisposed at a terminus of said linear arrangement, and wherein one ofsaid plurality of light emitting sub-pixels is a bottom sub-pixeldisposed at another terminus of said linear arrangement; (b) affixingsaid plurality of light emitting rigid chixels to a substrate in anarrangement that collectively provides a visible display having bothhorizontal and vertical directions in the plane of said visible display;(c) spacing said plurality of light emitting rigid chixels upon saidsubstrate to provide a pixel gap disposed across said non-functionaledges between the top sub-pixel of each adjacent light emitting rigidchixels in both said horizontal and vertical directions; (d) spacingsaid plurality of light emitting rigid chixels upon said substrate toprovide a second pixel gap disposed across said non-functional edgesbetween the bottom sub-pixel of each adjacent light emitting rigidchixels in both said horizontal and vertical directions; (e) spacingsaid pixel gap to be substantially equal to said second pixel gap. 12.The method of claim 11 additionally comprising the steps of: (a)disposing each of said plurality of light emitting rigid chixels uponsaid substrate such that the non-functional edge of any light emittingrigid chixel does not overlap the non-functional edge of any adjacentlight emitting rigid chixel.
 13. The method of claim 11 additionallycomprising the steps of: (a) providing a substantially transparent rigidsubstrate for each of said plurality of light emitting rigid chixels inwhich at least a portion of the light emitted by said light emittingrigid chixel is transmitted through said rigid substrate.
 14. The methodof claim 11 additionally comprising the steps of: (a) disposing at leasta portion of said plurality of light emitting rigid chixels upon saidsubstrate such that the non-functional edge of at least one lightemitting rigid chixel abuts the non-functional edge of an adjacent lightemitting rigid chixel.
 15. The method of claim 11, the one or more lightemitting pixels further characterized as a plurality of light emittingpixels, a first portion of said plurality of light emitting pixelseffective to produce a substantially red light emission, a secondportion of said plurality of light emitting pixels effective to producea substantially green light emission, and a third portion of saidplurality of light emitting pixels effective to produce a substantiallyblue light emission.
 16. The method of claim 15, further characterizedin that a fourth portion of said plurality of light emitting pixels iseffective to produce a substantially white light emission.
 17. Themethod of claim 11, the plurality of sub-pixels further characterized inthat a first portion of said plurality of sub-pixels is effective toproduce a substantially red light emission, a second portion ofsub-pixels is effective to produce a substantially green light emission,and a third portion of sub-pixels is effective to produce asubstantially blue light emission.
 18. The method of claim 17, furthercharacterized in that a fourth portion of sub-pixels is effective toproduce a substantially white light emission.
 19. The method of claim11, further characterized in that each of said plurality of lightemitting rigid chixels consists of one pixel.
 20. The method of claim11, further characterized in that each of said plurality of lightemitting rigid chixels consists of one pixel, and, each pixel consistsof: a red sub-pixel, a green sub-pixel, and a blue sub pixel.